Combined dry and finishing apparatus for molded pulp articles



Nov. 11, 1969 D. 1'. DANIELE 3,477,908

COMBINED DRY AND FINISHING APPARATUS FOR MOLDED PULP ARTICLES /A/.00A/ALD IMM/55g 5y KARL b5. FLocKs Arrow/EK Nov. 11, 1969 D. T. DANIELE3,477,908

COMBINED DRY AND FINISHING APPARATUS FOR MOLDED PULP ARTICLES Filed Jan.4, 1967 7 Sheets-Sheet 2 Nov. 11, 1969 D. T. DANIELE 3,477,908

COMBINED DRY AND FINISHING APPARATUS FOR MOLDED PULP ARTICLES gy KARLh). v -LOCKS #Tra/MEV D. T. DANIELE Nov. 11, 1969 COMBINED DRY ANDFINISHING APPARATUS FOR MOLDED PULP ARTICLES 7 Sheets-Sheet 4 Filed Jan.4, 1967 D. T. DANIELE Nov. 11, 1969 COMBINED DRY AND FINISHING APPARATUSFOR MOLDED PULP ARTICLES Filed Jan. 4, 1967 N .QQ

Hof 1 D. T. DANIELE Nov. 11, 1969 COMBINED DRY AND FINISHING APPARATUSFOR MOLDED PULP ARTICLES Filed Jan. 4, 1967 7 Sheets-Sheet 6 D. T.DANIELE Nov. 11, 1969 COMBINED DRY AND FINISHING APPARATUS FOR MOLDEDPULP ARTICLES Filed Jan. 4, 1957 7 Sheets-Sheet 7 U) lFLocKs UnitedStates Patent O U.S. Cl. 162-392 13 Claims ABSTRACT OF THE DISCLOSURE Acompound transfer pressing-heating die apparatus whereby wet pulppreforms are removed from a forming die, are both dried and finishedinto a condition for immediate use upon removal from the compoundtransfer pressing-heating die.

Apparatus for producing molded pulp articles with a smooth finish, inthe past have required a great deal of space t-o accommodate theforming, transfer, finishing and after-former presses, printers, etc.Since the initial de posited pulp has an extremely large water contentand complex molded shapes involve variable shrinkage and differentproduct control problems, there has always been a demand for a singleapparataus which would not only rapidly eliminate the residual moisturein the wet preform but would then immediately finish the articles (withdistinctive marks, colors, etc.) so that the articles are immediately ina condition for consumer use at maximum production rates.

Primary objects of the present invention comprise a novel compoundtransfer die for wet molded pulp preforms in which the wet preform issimultaneously dried and finished for immediate use; in which aplurality of compound transfer dies are movable in an orbital path forremoving wet pulp preforms from molding apparatus, and are molded in asub-orbital path in which cooperating portions of the compound die bothdry and nish the articles for immediate use by the consumer; in whichthe compound dies can be readily interchanged to provide readyconversion of the apparatus for use in the production of differentarticles; and in which the apparatus substantially eliminates mostproblems of production control including warpage, shrinkage and yetattains a high rate of production.

These together with other and more specific objects and advantages willbecome apparent from the following description when taken in conjunctionwith the drawing forming a part hereof, in which:

FIG. l is a diagrammatic side elevational view showing a molding wheelin relation to a transfer apparatus incorporating a plurality of thecompound transfer-dryinglinishing dies of the invention;

FIG. 2 is an enlarged, fragmentary sectional view taken substantially onthe plane of line 2 2 of FIG. 1 with portions broken away;

FIG. 3 is a view similar to FIG. 2 showing the transfer portion of thecompound die reoriented for mating engagement with its cooperatingpressing die;

FIG. 4 is a view similar to FIGS. 2 and 3 showing the transfer andpressing dies in mated relation;

FIGS. 5, l6 and 7 are sectional views taken on lines 5, 6 6 and 7 7 ofFIGS. 2, 3 and 4, respectively;

FIG. 8 is a side elevational view taken substantially on the plane ofline 8 8 of FIG. 2, and showing by phantom lines how a portion of thecompound die can be displaced for removal and/or replacement;

FIG. 9 is a fragmentary sectional view taken on the plane of line 9 9 ofFIG. 2;

3,477,908 Patented Nov. l1, 1969 ICC FIG. 10 is an enlarged sectiontaken substantially on the plane of line 10 10 of FIG. 4 and FIG. 1l isa diagrammatic view similar to FIG. 1 showing a modified embodiment ofthe compound transferheating-pressing dies.

Referring to the drawing in detail and first considering FIG. 1,apparatus for producing completely finished articles is indicatedgenerally at 10 and comprises suitable support structure 12 upon whichis mounted a molding wheel assembly y14, an article finishing assembly16, and article conveyor means 18.

The molding wheel assembly is generally conventional, and comprises asuitably journaled central shaft 20 upon which is mounted a plurality ofradially disposed suction dies 22 journaled at 23 on the supportstructure. The suction dies will include a plurality of fonaminous diesin a row extending the width of the wheel and suitable means (not shown)for communicating uid pressure and/or vacuum thereto will be provided.Each row of suction dies 22 will include an orienting arm 24 having aterminal cam follower 26 receiving a suitably conformed cam truck 28.

A slurry container 30 is disposed beneath the wheel 14 and each row ofdies 22 will be immersed in the slurry solution 32 in container 30 asthe dies are rotated with the wheel 14. The cam track 28 will orient therow of dies 22 at a take-off station 22 where a wet pulp preform, orvacuum deposed layer of pulp, will be removed by the article finishingassembly 16.

Means for synchronizing operation of the suction wheel assembly and/orfinishing assembly and/or supplying vacuum and/or pressurized air to theforming-pressing and finishing dies are generally conventional andspecific details thereof will not be illustrated in this application.

The article finishing assembly 16 comprises a plurality of compoundtransfer-pressing and finishing dies indicated generally at 34 andcorresponding to the number of forming dies 22. In a sense, each row ofcompound dies 34 is separate and distinct from the other. In itsbroadest context, the invention comprises a single compound diefunctioning in the manner to subsequently be described.

The assembly 16 includes a suitably journaled support shaft 36 and thecompound dies 34 are circumferentially spaced thereabout in radiallyextending relation.

As seen in FIG. 2, each of the compound dies 34 includes a support shaft38 having depending from opposite ends thereof support members 40 and42. Disposed outwardly of the shaft 38 and journaled at opposite endsand intermediate portions thereof, is a crank shaft 44 havingintermediate, offset, throw portions 46.

The throw portions 46 have journaled thereon connecting rods 48. Theconnecting rods are journaled by rods 50 to bracket portions 52 of amanifold member 54. The support members 40 and 42 includeguideway-bearings 58 and 60 respectively, reciprocably supportingcomplementary ends of the manifold member 54; see FIG. 10. The hollowchamber 56 is connected by suitable conduits 62 and 64 to a source o-fvacuum and/ or air, controlled in -any suitable manner in relation toheat and pressure communicated to a pulp article being nished.

The crank shaft incorporates an axial, keyed recess 66 mating with thedrive shaft of a suitable indexing drive means `68 comprising areversible motor of any suitable character; one of which for example,being -known in the trade as a Houdaille Hydroac component produced byHoudaille Industries, Inc. of 537 Delevan Ave., Buffalo, N.Y. When theindexing drive means is actuated the crank shaft 44 rotates 180 degrees,the manifold member 54 will be reciprocated radially with respect toshaft 38.

Secured to the member 54 by bolts 70 is a pressing die half 72 which isnormally urged outwardly by springs 74 circumposed bolts 70 and disposedbetween member 54 and the die half. The die half 72 includes an articlereceiving recess 76 conforming to the finished shape of one side of awet preform to be finished. The recess 76 communicates with internalducting 78; see FIG. 7, communicating with a pipe 80 communicating withchamber 56. Additionally, the die half will incorporate suitable heatingmeans such as a resistance heater plate 82 connected to leads 84connected to a suitable electrical supply source. The temperature ofplate 82 will be thermostatically controlled in any suitable manner.Accordingly, when a wet preform is subjected to both heat and pressure,as will be described, steam and Water will be evacuated or exhausted todry the article as the finishing assembly 16 roates.

A transfer die support shaft 86 extends between members 40 and 42 andhas pivotally supported at opposite ends thereof a transfer die-halfsupport casting including portions 88 and 90 flanking opposite sides ofthe outer end of supports 40 and 42; see FIG. 9, for example. Spacedfrom the shaft 86 and formed in portions 88, and members -40 and 42, arealignable apertures receiving therethrough a removable coupling pin 92.The casting portions 88 and 90 have fixed thereto a reversible indexingdrive means 94 operated in any suitable manner and adjusted toreversibly rotate a transfer die carrier 96 one hundred and eightydegrees. The transfer die carrier 96 is fixedly keyed on a hollow shaft98 having a terminal, axial bore keyed to the drive shaft 100 of theindexing drive means 94. The transfer die carrier includes at oppositesides thereof abutment elements 102 and 104 projecting radially from theshaft 98. The elements 102 and 104 have an arcuate surface complementaryto the outer surface of shaft 86, and when the indexing drive means 94is actuated, the transfer die carrier 96 will be repositioned from theposition shown in FIG. 5; where a wet preform is received thereon, tothe position shown in FIG. 6, where the wet preform is disposed inopposing confronting relation with respect to the finishing die 72.

The transfer die carrier 96 is connected to the hollow shaft 98 and tosuitable conduits and ports 106 (not shown) for communicating with atransfer die half 108 which is ported and has an article receivingsurface 110 complementary to the recess 76. The transfer die includes athermostatically controlled heater plate 112 connected to a suitablesource of electrical energy by leads 114.

`Considering FIGS. 5-7, a still wet pulp preform P is formed on thesuction or forming dies 22 and is indexed at position 22. At this time,through the medium of reversing vacuum and air pressure in the die 22,the wet preform will be transferred. At the same time, the transfer die108 will be disposed in engaged relation on the exposed surface of thepreform. The indexing drive means 94 will be actuated, and at the sametime vacuum is communicated to the transfer die half 108. The preform isthen oriented to the position shown in FIG. 6. The vacuum applied to thedie half 108 will not only serve to retain the preform P thereon, butwill also serve to remove steam and residual moisture from thestill-damp preform.

Next the indexing drive unit 68 will be actuated whereby the crankshaft44 will be rotated 180 degrees causing mating of the die halves 72 and108, as seen in FIG. 7. It will be noted that after a predeterminedpressure exists between the dies, the springs 74 will be compressed toprevent damage between the engaged dies.

The heater plates 82 and 112 of the respective dies will cause theresidual moisture to become vapor and cornmunication of vacuum to therespective dies will remove steam and water vapor from the articlesbeing finished. The finishing die recess 76 may be so conformed to ashape for the purpose of reforming the shape of the preform P, i.e.,incorporating indicia, unusual fianges, recesses, etc. Further, theapplication of both heat and pressure on the wet preform results inironing or calendering the article to finish with a smooth and softfinish resulting from reorienting to loosely interdigitated fibers ofthe preform initially deposited on the suction dies 22.

Each of the compound dies 34; see FIGS. 1 and 8, for example, occupy asegment of a primary orbit about the shaft 36. While the transfer diehalves 108 are moved through a suborbital path from station 22 to thatof 34'; see FIG. 1, the die halves 72 and 108 remain in engagement asufiicient period of time to completely finish the preform P forimmediate use by the consumer. As shown at 34, after the preform iscompletely finished as article F, the indexing drive means 68 and 94 areonce more actuated, i.e., reversed, the die halves separate, and throughthe medium of suitable air pressure control valves, the finishedarticles F are deposited onto the conveyor means 18. The die half 108will now be in a position to receive another wet preform thereon atstation 22.

Referring to FIG. 11, a modified finishing assembly is showndiagrammatically at 200. Similar reference numerals will be used toidentify previously described structure, and such structure will not befurther described with reference to FIG. 11. The molding wheel assembly14 and conveyor means 18 are similar to those previously described an'dare generally conventional.

The finishing assembly 200 includes a plurality of compound dies 234,and although the die halves 272 function in the same manner as diehalves 72, die halves 308 are of a different construction. The diehalves are multiface, i.e., include at about shaft 298 transfer andfinishing recesses 310 and 310'.

The wet preform is initially received in recess 310 and the articles aremoved through a primary orbit of 720 ydegrees about shaft 236. The first360 degrees of rotation affords predrying of the preforms and sprayingof waxes, dyes, etc. at stations A and B through the use of spraynozzles mounted on an arcuate adjustable hood H deposed about asubstantial portion of the major orbit of the compound dies. The hood Hcan incorporate suitable auxiliary heating means L such as banks of heatlamps or the like, and the hood H can be adjusted in spaced relationfrom the exposed preforms by means of cable and winch assemblies W.Through the medium of the hood H predrying of the articles can beprovided, coatings of waxes, dyes and/ or other finishing materials canbe applied to the exposed preforms.

During the next 360 degrees of rotation of the compound dies, thepreviously described indexing means, rotate recesses 310 and 310 onehundred eighty degrees for cooperation with the finishing dies 272whereafter the finished articles are deposited on conveyor means 18.

The compound dies 72, 108 and 272 and 308 can be readily removed andchanged, i.e., for conversion and producing different articles, i.e.,meat trays, egg cartons, etc. Due to space limitation change of the dies72, 272 and 108, 308 would normally be extremely time consuming. Wherethe apparatus must be shut down for a relatively long period, productionis lost and this results in expensive loses. However, in both types ofapparatus disclosed, and as readily seen in FIGS. 8 and 9, for example,the pins 92 can be withdrawn from the aligned apertures in members 40,42 and casting portions 88, 99 whereby the transfer die carrier 96pivoted to the phantom line position shown, the dies can be removed,replaced and/or repaired and ready access is afforded to the innerfinishing dies 72 for the same purposes.

It will be obvious to those skilled in the art that various changes maybe made without departing from the scope of the invention and theinvention is not to be considered limited to what is shown in thedrawings and described in the specification.

What is claimed is:

1. In a molded pulp finishing assembly, means for supporting saidassembly for rotation about an axis of rotation, said assemblycomprising a plurality of compound finishing dies circumferentiallyspaced about said axis of rotation, said compound .finishing diescomprising a transfer -die half and a finishing die half, said diehalves including complementary molding portions for sandwichedengagement on a pulp preform disposed therebetween, means supportingsaid finishing die half for movement toward and away from said transferdie half, and

means dsplaceably supporting said transfer die in an orbit of rotationof substantially "180 and spaced from usaid finishing die from aposition for receiving a wet pulp preform to a position in directopposed relation to said finishing diehalf.

2. The structure as claimed in claim 1 in which at least one said diehalf includes means for heating the pulp preform being finished.

3. The structure as claimed in claim 2 in which at least one of said diehalves includes means for exhausting water vapors away from dies when apreform is heated and passed therebetween.

4. The structure as claimed in claim 1 including independent indexingdrive means operatively connected to said respective die halves. p

5. A finishing assembly for use with apparatus for continuously formingpulp preforms comprising:

a plurality of compound dies disposed in radially extending relationabout an axis of rotation defining a major axis of rotation,

said compound dies comprising a finishing die half and a transfer diehalf, said transfer dievhalves being disposed in radially spacedrelation outwardly from a corresponding finishing die half,

means connected to said finishing die halves for moving said finishingdie half into engagement with a corresponding transfer die half,

means on said transfer die half for moving said transfer die half in asub-orbit defined by a pivot axis, disposed radially outwardly of saidfinishing die half,

said finishing die half including at least one surface positionableeither radially outwardly for receiving a wet pulp preform, or radiallyinwardly for engagement with said finished die half for producing afinished article.

6. A finishing assembly as claimed in claim 5 in which at least one ofsaid die halves includes heating means for drying pulp preforms.

7. A finishing assembly as claimed in claim 6 in which at least one ofsaid die halves includes means for expressing steam and water vapor awayfrom said compound dies.

8. A finishing assembly as claimed in claim 5 in which said finishingdie half is spring mounted whereby only a predetermined pressure can beexerted between said cornplementary die halves.

9. A finishing assembly as claimed in claim 5 in which said transfer diehalf comprises a die carrier pivotally mounted at one edge, and lock pinmeans displaceably engaged with said carrier for permitting ready accessto each of said finishing and transfer die halves.

10. A finishing assembly as claimed in claim 5 in which said transferdie half includes opposed transfer die portions disposed at degreeintervals, each of said transfer die portions being engageable with saidfinishing die half.

11. A finishing assembly as claimed in claim 10 including a hood over aportion of the major orbit of said compound dies, at least one of saidtransfer die portions being directed toward said hood during movement ofsaid transfer dies in their major orbit, said hood including means fortreating a preform during movement of said transfer dies thereby.

12. A finishing assembly as claimed in claim 5 in which each of saidfinishing dies includes a crank shaft and connecting rod, and an indexdrive means operatively connected to each of said respective crankshafts.

13. A finishing assembly as claimed in claim 5 in which each of saidtransfer dies includes an independent indexing drive means for orientingthe transfer die half between a radially outward and radially inwardposition, said transfer die half including a transfer die carrierpivotally outwardly of a respective finishing die, said carrierincluding spaced abutment means extending radially from opposite sidesof the pivot axis of the carrier at 180 intervals, and a support shaftdisposed in the path of travel of said carrier abutment means forengagement with at least one of said abutment means.

References Cited UNITED STATES PATENTS 2,746,358 5/1956 Emery 162-3922,772,608 12/1956` Emery 162-392 3,132,991 5/ 1964 Hornbostel et al.162-392 HOWARD R. CAINE, Primary Examiner U.S. Cl. X.R.

